Claas RU-450 XTRA (660) Forage Harvesters Repair Manual DE

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– 00 0297 858 0.pdf

00 0297 858 0.pdf

Table of Content:
1 Repair Manual
2 CLAAS RU 450
4 groups overview
5 1 General information
6 2 snail trough
7 3 machine frame
8 4 knives / feeder
9 5 Hydraulics
10 6 Special equipment
11 7 drives
12 8 cardan shafts / couplings
14 General information
14.1 Introduction
15 This CLAAS REPAIR MANUAL is intended to help ensure constant operational readiness and thus the…
16 experiences of our customer service technicians and factory experiences are in this REPAIR MANUAL…
17 The sequence of images shows the sequence of a repair process, the text provides the necessary information for d…
18 The essential repairs are listed in such a way that individual and small work is also included…
19 It will be supplemented by supplements in accordance with the technical development of the machines and …
20 To be on the safe side, please always compare the setting values …
21 CLAAS KGaA mbH Customer Service
22 General information
23.1 Introduction to the CLAAS repair manual
24 The CLAAS REPAIR MANUAL is divided into chapters that follow the order of the CLAAS SPARE PARTS…
25 In each chapter the images and pages are numbered consecutively from 1 onwards. When numbering…
26 Those assembly processes that only apply to certain machine types are specified by type…
27 The order of the additions is indicated by an additional number, which is marked with a cross…
28 The symbols are used for quick orientation during recurring assembly processes. A picture…
29 Under the heading GENERAL REPAIR INSTRUCTIONS at the beginning of this manual are informative…
29.1 Particular attention should be paid to
30 The information in these operating instructions must be followed by all persons in order to not originally come from CLAAS …
33 For damage caused by the use of non-CLAAS original parts, accessories and accessories…
34 Technical information, dimensions and weights are non-binding. Technical information, dimensions and weights v…
35 Front, rear, right and left always applies in the direction of travel.
35.1 Nameplate
37 The type plate (1) with the machine number is on the right side on the rear wall of the machine…
38 (Fig.1)
39 For all spare parts orders and technical queries, provide the machine number, type and …
39.1 General repair instructions
40 1. Identify the cause of damage, isolate the event of damage and secure the machine.
41 2. Use original CLAAS spare parts and appropriate CLAAS special tools.
42 3. When dismantling the gearbox, first drain the oil and then remove the gearbox. Fixed…
43 4. Tension steel roller chains:
44 steel roller chains are correctly tensioned when the slack strand is under low load on the load carrier…
45 Example: Center distance 500 mm = indentation distance on the slack side approx. 10 mm.
46 5. Taper ring connections:
47 cone ring connections are safe even when large forces are transmitted from the drive element to the shaft…
48 Dismantling:
49 After loosening the axial clamping, tighten the cone ring connections with an impact tube and strong pressure…
50 NOTE! The inner diameter of the impact tube must be large enough to reach over the cone ring.
51 Assembly:
52 During assembly it is important that the shaft, hub, feather key and cone rings are thoroughly cleaned, m…
53 NOTE! Do not mount parts with viscous grease.
54 6. Self-locking screws (with micro-encapsulated adhesive)
Replace 55 self-locking screws, e.g. Verbus Plus / ImbusPlus or similar, with each assembly. You are…
56 self-locking screws with microencapsulated adhesive always quickly to the specified tightening torque…
57 Instead of self-locking screws, in indivih microencapsulated adhesive can only be used where the B…
59 The full load capacity of these screws is reached after 24 hours at +20 C. The full…
60 7. Liquid screw locking agent (e.g. DeloML 187 / Loctite 242 or similar)
61 Only use liquid screw locking where specified by the manufacturer.
62 Correct application:
63 Metallic connections that are to be used with liquid screw locking must…
64 Before applying the liquid screw locking agent, the metallic surfaces must be cleaned of the activator…
65 For screw connections, use liquid screw locking if possible only on the internal thread (nut) …
66 Note: If the liquid screw locking agent is applied to the threaded bolt or at the start of the thread on…
67 screw connections secured with liquid screw locking can be easily loosened…
68 8. Install clamping ring bearings correctly Clamping ring bearings are insta specially machined bearing…
70 10. Cutting ring screw connections on hydraulic lines For all pre-assemblies and pre-assembled at the factory…
71 11. Progressive ring screw connections on hydraulic lines For all pre-assemblies as well as from the factory…
72 12. Sealing cone screw connections on hydraulic lines Assembly: Oil the O-ring on the sealing cone. …
73 13. Welding work
74 NOTE! Proceed as follows for all electrical welding work on the machine:
75 Turn off battery disconnect switch!
76 Disconnect the plug connection to the screen.
77 Pull out the electrical plug-in modules in the central electrical system.
78 Disconnect the electrical plug connections between thf the repair!
81.1 Symbol explanation
82 This CLAAS REPAIR MANUAL contains some symbols from the Symbol Overview DIN 30…
83 The meanings of these symbols will quickly be memorized by the user. They should help…
84 Dismantle
87 Prevent material damage
88 Disassemble
90 Special tool _x0005_use
91 Assemble
93 Drain drain opening
94 Install
95 Cultivate
96 Eye, check _x0005_check
98 Filling opening
100 Unlock, Secure
101 Overflow
102 Balancing
103 Liquid Securing, Gluing Sealing
105 Conditional
106 reusable
107 Substructure
108 Support
109 Interception
110 At every assembly
111 Replace
112 Installation direction
114 General information
114.1 For safety
115 Important information relating to the safety of operating personnel and the vehicle is contained in this…
116 Identification of instructions which, if ignored, pose a danger to the life and limb of th18 Identification of instructions that, if ignored, could cause damage to the machine.
119 Measures to avoid danger to the machine.
120 Marking of information that enables more effective and economical use of the machine…
121 Marking of instructions which, if ignored, pose a risk to the environment. An environment…
121.1 Important working instructions
122 Repair, maintenance and cleaning work and the elimination of malfunctions gru…
123 When carrying out repair, maintenance and cleaning work on the raised attachment, always secure…
123.1 Hydraulic system
124 When working on the hydraulic system, be sure to depressurize it.
125 Fluid escaping under high pressure (hydraulic oil, etc.) can penetrate the skin and cause heavy…
126 Dispose of oils and fats properly!
127 Check hydraulic hose lines regularly and replace them if they are damaged or aging…
128 Repair work on the hydraulic system may only be carried out by authorized specialist workshops…
128.1 Screws
129 Check all screws for tightness and tighten if necessary.x000D_
130 Check whether all split pins and dowel pins are present.
131 The specified lubrication times only apply to normal operating conditions. If the machine is under …
132 General information
145.1 Technical data
146 Front, rear, right and left always applies in the direction of travel.
147 Technical information, dimensions and weights are with _x0004_corresponding tolerances.
149 Working position
150 width:
151 Length:
155 Transport position
156 width:
157 Height:
161 Weight
163.1 Oil filling quantities for the gearbox
164 This information applies to the RU 450 maize headers from machine number: 660 0 1001
165 Gear type
166 oil type
167 Filling quantity
168 input gear (A) switchable
169 input gear cannot be switched
170 multi-purpose gear oil SAE 90
171 (MIL-L-2105) Use API-GL-90
172 2.5 liters
173 0.85 liters
174 Main gear (B)
175 multi-purpose gear oil SAE 90
176 (MIL-L-2105) Use API-GL-90
177 1.8 liters
178 bevel gear (C)
179 Multi-purpose gear oil SAE 90
180 (MIL-L-2105) Use API-GL-90
181 0.8 liters
182 angular gear (D)
183 Multi-purpose gear oil SAE 90
184 (MIL-L-2105) Use API-GL-90
185 0.45 liters
186 Rotor Gear (F)
187 Multi-purpose gear oil SAE 90
188 (MIL-L-2105) Use API-GL-90
189 3.5 liters
190 clearing gear (G)
191 Multi-purpose grease (fluid grease) K 2 K
Use 192 according to DIN 51825
194 manual transmission (H)
195 (Optional)
196 Multi-purpose gear oil SAE 90
197 (MIL-L-2105) Use API-GL-90
198 3.5 liters
199 Angle gear for storage corn screws (maintenance-free)
200 multi-purpose gear oil SAE 90
201 (MIL-L-2105) Use API-GL-90
202 0.2 liters
203 Tightening torques (in Nm) of hexagonal screws, cylinder head screws and hexagonal nuts
204 screws and nuts
205 blackened, phosphated or galvanized
206 strength class
210 hexagon screws DIN 931 DIN 933
211 cylinder head screws DIN 912
212 hexagon nuts DIN 934
213 Dimensions
214 Metric standard thread
262 1080.0
265 1400.0
266 1650.0
268 1260.0
269 1800.0
270 2160.0
271 Dimensions
272 Metric fine thread
273 hexagon screws DIN 960 DIN 961
274 hexagon nuts DIN 934
275 M 8 x 1
277 35293 190
295 M 16 x 1.5
299 M 18 x 1.5
303 M 20 x 1.5
307 M 22 x 1.5
311 M 24 x 2
315 M 27 x 2
319 M 30 x 2
323 ATTENTION! Cadmium-plated or copper-plated screws and nuts must be tightened with torques that are 2…
324 tightening torques for hydraulic screw connections with O-ring according to ISO 6149
325 Dimensions
326 Tightening torque according to ISO 6149
327 M 8 x 1
328 7+2 Nm
329 M 10 x 1
330 11+4 Nm
331 M 12 x 1.5
332 16+5 Nm
333 M 14 x 1.5
334 23+8 Nm
335 M 16 x 1.5
336 29+10 Nm
337 M 18 x 1.5
338 38+13 Nm
339 M 20 x 1.5
340 46+15 Nm
341 M 22 x 1.5
342 67+22 Nm
343 M 24 x 1.5
344 86+29 Nm
345 M 26 x 1.5
346 103+34 Nm
347 M 27 x 2
348 103+34 Nm
349 M 30 x 2
350 170+57 Nm
351 M 33 x 2
352 200+67 Nm
353 M 36 x 2
354 245+82 Nm
355 M 38 x 2
356 245+82 Nm
357 M 39 x 2
358 310+103 Nm
359 M 42 x 2
360 380+127 Nm
361 M 45 x 2
362 440+147 Nm
363 General information
364.1 Machine overview RU 450
365 1. Instruction bar
366 2. Feed disks
367 3. Blade discs (counter-rotating)
368 4. Clearing discs
369 5. Feed cone
370 6. Feeder snail
371 7. Snail trough
372 8. Outside tip right
373 9. Outside tip left
374 10. Intermediate peaks
375 11. Divider tips
376 12. Drive side feed screw
377 General information
379 Snail trough
395.1 Snail trough
396.1 Protective cover left. and re. dismantle and grow
397 Remove the lower protective cover (1) = unscrew 2 hexagon screws.
398 Attachment of the protective cover: Insert the 3 metal tabs into the slots of the upper protective cover (2) and…
399 (Fig.1)
401 Remove the upper protective cover (3) = unscrew 6 hexagon screws.
402 Assembly of the upper protective cover (3): Insert the fold at the top under the edge of the frame and de…
403 (Fig.2)
404.1 Removing and installing instruction brackets and bracket supports
405 Dismantling: Left on the outside of the support arm. and re. dismantle the bracket supports(1). Attached with 4 hexagons…
407 A helper is required for this work.
408 Fig.3 shows the attachment of the left bracket support.
409 Attachment of the bracket support to the support arm on the left. and right: Set the bracket support (1) directly onto the support arm…
410 At the points where the protective railing (3) and the protective cover (2) are attached together with the support arm…
411 Disassemble/assemble the instruction bracket at the front of the bracket support (1), 2 hexagon screws M10x85 with …
412 (Fig.3)
413.1 Removing/installing the middle guide bar and guide tube
414 Dismantle the guide bracket (6) and guide tube (5) by loosening 2 M10 hexagon screws on the support…
415 Mount the instruction bracket on the support of the auger trough with 2 hexagon screws M10x80, with …
416 Mount the orientation tube on the holder of the orientation bracket with 2 hexagon screws M10x80, with Co…
417 (Fig.4)
418.1 Replacing inlet segments
419 The inlet segments left. and re. On the outside of the partition walls of the snail trough are the S…
420 The (Fig.5) shows the position of the screws at the front in the support of the screw trough (view from below).
422 To dismantle the inlet segment, fold up the side arms.
423 Screw on the inlet segment with 2 hexagon screws M8x20 and contact washer B8.
424 (Fig.5)
425.1 Replace inlet segment in the middle inside
426 The inlet segment is inserted into the rear wall of the snail mulch. At the front there are…
427 First unscrew the guide (8), then the inlet segment (9).
428 Screw on the new inlet segment (9) with 2 hexagon screws M8x20 and contact washer B8. There…
429 (Fig.6)
430.1 Replace inlet counterblades.
431 Each left. and re. There are inlet counter-cutters under the front supports, a total of 4 pieces, ang…
433 To remove the inlet counter blade, fold up the side arms.
434 The new counter blades (e.g. (11)) each with 2 hexagon screws M10x16 (12) and contact washer …
435 Arrangement of the counter blades: – left outside = 992 176.0 left (10) – left inside = 992 175.0 inn…
436 (Fig.7)
437.1 Changing and adjusting baffles
438 The baffles (14) are on the left. and re. attached to the front of the auger trough.
440 To unscrew or adjust the baffle, fold up the side arms.
441 Screw on the guide plate (14) with 3 hexagon screws (13) M8x16 and contact washer A8.
442 Note: Align the guide plates according to the feed cones, the fold must point outwards….
443 (Fig.8)
444.1 Change inlet plates
445 The inlet plates are on the left. and re. on the bottom of the snail trough.
446 In order to disassemble/assemble the inlet plate on the right side, the protective cover must first be dismantled…
447 (Fig.9) shows the dismantling of the protective plate (15) under the auger trough.
448 (Fig.9)
450 To dismantle the inlet plate (16), unscrew the 4 M8 countersunk screws.
451 To do this, use a 6 mm Allen key with an extension.
452 In the (Fig.10) you can see the loosening of the rear countersunk screws with the attachment removed.
453 (Fig.10)
455 Under the auger trough, tighten the nuts (17) with a 13 mm socket wrench with extension…
456 Unscrew the two M8 hexagon screws (18) from below.
458 A helper is required for this work.
459 (Fig.11)
461 Unscrew the front 2 countersunk screws (19) and fold up the side arms.
462 (Fig.12)
464 Install the new inlet plate (16) in the reverse order as described during disassembly….
465 Fastening is done with 4 countersunk screws M8x20 with hexagon socket, with contact washer A8 and…
466 (Fig.13)
467.1 Change wiper
468 The wipers (21) are located on the left side. and re. on the inner wall of the screw trough (22).
469 Unscrew the worn wipers.
470 Screw on the nine wipers each with 3 hexagon screws M8x16 and contact washer A8.
472 When installing, pay attention to the correct position of the wipers. The angled part should be inward…
473 (Fig.14)
497 Snail trough
500 machine frame
517.1 Machine frame
518.1 Removing and installing locking
519 Remove the safety pin (1) from the pull rod (2). The pull rod from the bearing point on the ha…
520 Turn the retaining screw for the hand lever (3) out of the machine frame. Remove the hand lever (3).
521 (Fig.1)
523 Pull the split pin out of the bolt on the fork head (4). Pull the bolt (5) out of the fork head bearing…
524 (Fig.2)
526 Loosen the lock nut and unscrew the fork head (4) from the tie rod (2).
527 Check pull rod and hand lever, adjust if necessary.
528 Screw the fork head back onto the pull rod.
529 (Fig.3)
531 Reconnect the pull rod and hand lever.
532 Further work is carried out in the reverse order as for removal.
533 Adjust the closing angle of the lock on the fork head (4). The fork head with the lock nut…
Insert 534 bolt and secure with washer and split pin.
535 Check the correct function of the locking!
536 (Fig.4)
537.1 Support arm left. and re. removing and installing
538 Start this work with the following measures:
539 1. Jack up the machine frame (screw trough) horizontally and align it.
540 Note: Use a spirit level (1) to measure the middle cutting device, see Fig.5. Di…
541 Make sure to measure exactly to the transverse axis. Align the machine exactly as shown in Fig.6…
542 (Fig.5-6)
544 2. Remove instruction bracket and bracket holder.
545 3. Remove protective guard and protective cover.
546 4. Remove the protective cover at the top and bottom of the auger trough.
547 5. Remove the feed disks, feed cone, knife disk, clearing disks and clearing gear.
548 6. Remove the outside tips or storage corn auger, complete with the tip supports.
549 7. Remove the grinding skid (4) from the rotor gear.
550 8. Remove the outside duct floor (2).
552 9. Remove conveyor gear (3).
553 (Fig.7)
556 Start removing the angular gear (3) by dismantling the drive shaft (5). At the cross…
557 (Fig.7-8)
558.1 Remove rotor gearbox
559 Screw an M12 eyebolt (6) into the thread of the rotor gear shaft. The rotor gear with …
560 Loosen the 4 hexagon screws (7) on the rotor gear flange.
561 (Fig.9)
563 Completely unscrew the 4 hexagon screws (7) on the rotor gear flange.
564 The 2 hexagonal screws M10 (8) to protect the forcing thread, left. and re. on the gearbox flange e…
565 (Fig.10)
567 Two long hexagon screws (9), e.g. M 10 x 80 DIN 933, left. and re. into the forcing thread on G…
568 Pull the rotor gear evenly out of its seat (dowel pins). The gearbox with the hoist…
569 (Fig.11)
571 Gearbox repair see chapter: 7.8/1
573 Push through the 2 dowel pins (10) of the rotor gear inwards. The 2 dowel pins from the Tra…
575 If the angular gear and the wedge clutch are not removed, the dowel pins must…
576 (Fig.12)
577.1 Install rotor gearbox
578 Note direction of rotation
579 When installing, pay attention to the direction of rotation of the gearbox. Because of the freewheel, turn left and right…
580 With an angular gear and wedge clutch installed, connect the rotor gear (11) to the drive shaft…
581 (Fig.13)
583 Screw the 4 hexagon screws M16 x 45 (12) with contact washer A16 into the flange connection…
584 (Fig.14)
586 Align the rotor gear and 2 dowel pins 12 x 45A (13) left. u. re. into the flange connection …
587 Then tighten the 4 hexagonal screws M16 (13) with the tightening torque according to the table on page 1.4/3 …
588 To protect the extraction thread, screw the 2 hexagon screws M10 x 20 back in and tighten.
589 (Fig.15)
590.1 Remove angular gear with wedge clutch
591 Remove the angular gear by loosening and unscrewing the 4 hexagon screws M12 (14) on the Wi…
592 (Fig.16)
594 After unscrewing the screws, knock in the two dowel pins (16) on the device flange…
595 (Fig.17)
597 If the rotor gear is removed, drive the angle gear by hitting it with a shoe…
598 (Fig.18)
600 If the rotor gear is still installed, loosen the angle gear by levering on the gearbox…
601 Have a helper secure the angle gear (15). The angular gear together with the Ke…
602 (Fig.19)
604 Gearbox repair see chapter: 7.10/1
605.1 Installing an angular gearbox with a wedge clutch
606 Drive new dowel pins, 2 pieces 12 x 45A, into the gearbox flange until they touch the front edge…
607 Lift the angle gear complete with the mounted wedge clutch onto the support tube.
608 Insert the 4 hexagon screws M 12 x 60 (16) with contact washers A12 on the gearbox flange into the support…
609 (Fig.20)
611 Align the gearbox and drive the 2 dowel pins into the support tube.
612 Tighten the screws with a torque wrench. Tightening torque according to table on page 1.4/3.
613 (Fig.21)
614.1 Change wedge clutch
615 Clamp the removed bevel gear in a vice. The clamping screw (hexagon socket screw…
616 Remove the wedge clutch completely from the angle gear.
617 (Fig.22)
619 Clutch repair see chapter: 8.1/1
621 Place the new or repaired wedge clutch on the output shaft of the angular gear.
623 Pay attention to the direction of rotation!
624 Make sure that the locking screw (2) is positioned again in the same place as…
625 Note: The shaft is drilled.
626 Tighten the clamping screw again.
627 (Fig.23)
628.1 Remove support tube
629 Loosen the 6 hexagon screws (1) on the connecting flange between the support arm (2) and the support tube (3). Z…
630 (Fig.24)
632 Hang the support tube (3) in a hoist. Unscrew the remaining 2 hexagon screws.
633 Note: Spacer plates are inserted between the support arm and the support tube to ensure the exact fit and friction…
634 Remove the support tube (3) from the support arm (2).
635 (Fig.25)
636.1 Install support tube
637 Guide a new or revised support tube to the support arm using a hoist.
638 Insert the spacer plates (4) marked during removal in the correct position between the support tube and support arm…
639 (Fig.26)
641 Screw all 6 hexagon screws M16 x 45 (1) with contact washer A16 into the flange connection…
642 Note: Make sure that the spacer plates are level and in the correct position.
643 (Fig.27)
645 Align the support tube exactly horizontally using a spirit level (5).
646 Align the support tube in its longitudinal direction parallel to the machine.
647 (Fig.28)
649 Swing the support arm up and down to check the fit of the centering screw (6).
650 Adjust the centering screw so that the support arm is horizontal and parallel to the machine. …
651 Note: Spacer plates with a thickness of 1 and 2 mm are available to correct the settings.
652 (Fig.29)
654 If all adjustment work has been completed correctly, the hexagon screws on the flange must…
655 (Fig.30)
656.1 Remove support arm
657 First remove the hydraulic cylinder, see Chapter 5.1/1
658 Unscrew the bracket (1) for the torque arm from the support arm.
659 (Fig.31)
661 Remove the cover plate (2) from the support arm.
662 (Fig.32)
664 Hang the support arm (3) in a lifting gear and secure it.
665 (Fig.33)
667 Unscrew the grease nipples (4) from the hexagon screw of the support arm bearing at the front and rear.
668 Check the grease nipple for continuity. Replace damaged grease nipples!
669 (Fig.34)
671 Loosen and remove the M16 lubrication screw (5) on the front bearing pin of the support arm.
672 Clean the hexagon screw (lubricating screw = blow through the hole) and the spacer.
673 Clean the fitting washers and, together with the cover washer and the hexagon screw, put them back together…
674 (Fig.35)
676 Loosen and unscrew the M16 lubrication screw (5) on the rear bearing pin of the support arm.
677 Clean the hexagon screw (lubricating screw = blow through the hole) and the spacer.
678 (Fig.36)
680 Also attach the support arm to the rear of a hoist.
681 Loosen and unscrew the 3 hexagon screws on the retaining plate (6).
682 Remove the retaining plate.
683 (Fig.37)
685 Lift off the support arm (3).
686 Check the bearing bushes (11) in the screw trough for wear. Replace defective bearing bushes…
687 Press in new bearing bush on the outside flush with the bearing seat.
688 (Fig.38)
689.1 Install support arm
690 Use the retaining plate (6) to check whether the bearing pins can be moved easily. Bearing bushes and L…
691 (Fig.39)
693 Insert the repaired or new support arm with the bearing pin at the front.
694 (Fig.40)
696 At the rear, attach the support arm to the holding plate (6) with 3 hexagon screws M12 x 45, contact washer A12 …
697 Tightening with a torque wrench. Tightening torque according to table on page 1.4/3.
698 (Fig.41)
700 Hold the cover plate (8) and insert the bolt (7) for the upper hydraulic cylinder fastening…
701 Mount the hydraulic cylinder, see chapter 5.1/8
702 The bracket for the torque arm with 2 hexagon screws M12 x 35 with lock nut V…
703 (Fig.42)
705 At the front, on the bearing journal, the washer, contact washer A16